Plated terminations

ABSTRACT

Improved termination features for multilayer electronic components are disclosed. Monolithic components are provided with plated terminations whereby the need for typical thick-film termination stripes is eliminated or greatly simplified. Such termination technology eliminates many typical termination problems and enables a higher number of terminations with finer pitch, which may be especially beneficial on smaller electronic components. The subject plated terminations are guided and anchored by exposed internal electrode tabs and additional anchor tab portions which may optionally extend to the cover layers of a multilayer component. Such anchor tabs may be positioned internally or externally relative to a chip structure to nucleate additional metallized plating material. External anchor tabs positioned on top and bottom sides of a monolithic structure can facilitate the formation of wrap-around plated terminations. The disclosed technology may be utilized with a plurality of monolithic multilayer components, including interdigitated capacitors, multilayer capacitor arrays, and integrated passive components. A variety of different plating techniques and termination materials may be employed in the formation of the subject self-determining plated terminations.

PRIORITY CLAIM

This application claims the benefit of previously filed U.S. ProvisionalPatent Application entitled “PLATED TERMINATIONS,” assigned U.S. Ser.No. 60/372,673, filed Apr. 15, 2002, and which is incorporated herein byreference for all purposes.

BACKGROUND OF THE INVENTION

The present subject matter generally concerns improved terminationfeatures for multilayer electronic components, and more particularlyrelates to plated terminations for multilayer capacitors or integratedpassive components. The subject termination design utilizes selectivearrangements of internal and/or external electrode tabs to facilitatethe formation of plated electrical connections. The external connectionsare preferably made whereby the provision of typical thick filmtermination stripes is eliminated or greatly simplified.

Many modern electronic components are packaged as monolithic devices,and may comprise a single component or multiple components within asingle chip package. One specific example of such a monolithic device isa multilayer capacitor or capacitor array, and of particular interestwith respect to the disclosed technology are multilayer capacitors withinterdigitated internal electrode layers and corresponding electrodetabs. Examples of multilayer capacitors that include features ofinterdigitated capacitor (IDC) technology can be found in U.S. Pat. Nos.5,880,925 (DuPré et al.) and U.S. Pat. No. 6,243,253 B1 (DuPré et al.).Other monolithic electronic components correspond to devices thatintegrate multiple passive components into a single chip structure. Suchan integrated passive component may provide a selected combination ofresistors, capacitors, inductors and/or other passive components thatare formed in a multilayered configuration and packaged as a monolithicelectronic device.

Selective terminations are often required to form electrical connectionsfor various monolithic electronic components. Multiple terminations areneeded to provide electrical connections to the different electroniccomponents of an integrated monolithic device. Multiple terminations arealso often used in conjunction with IDC's and other multilayer arrays inorder to reduce undesirable inductance levels. One exemplary way thatmultiple terminations have been formed in multilayer components is bydrilling vias through selected areas of a chip structure and filling thevias with conductive material such that an electrical connection isformed among selected electrode portions of the device.

Another way of forming external terminations for the subject devices isto apply a thick film stripe of silver or copper in a glass matrix toexposed portions of internal electrode layers, and subsequently platingadditional layers of metal over the termination stripes such that a partis solderable to a substrate. An example of an electronic component withexternal electrodes formed by baked terminations and metal films platedthereon is disclosed in U.S. Pat. No. 5,021,921 (Sano et al.). Theapplication of terminations is often hard to control and can becomeproblematic with reduction in chip sizes. U.S. Pat. Nos. 6,232,144 B1(McLoughlin) and 6,214,685 B1 (Clinton et al.) concern methods forforming terminations on selected regions of an electronic device.

The ever-shrinking size of electronic components makes it quitedifficult to print termination stripes in a predetermined area withrequired precision. Thick film termination stripes are typically appliedwith a machine that grabs a chip and applies selective terminations withspecially designed wheels. U.S. Pat. Nos. 5,944,897 (Braden), U.S. Pat.No. 5,863,331 (Braden et al.), U.S. Pat. No. 5,753,299 (Garcia et al.),and U.S. Pat. No. 5,226,382 (Braden) disclose mechanical features andsteps related to the application of termination stripes to a chipstructure. Reduced component size or an increased number of terminationcontacts for an electronic chip device may cause the resolution limitsof typical termination machines to become maxed out.

Other problems that can arise when trying to apply selectiveterminations include shifting of the termination lands, mispositioningof terminations such that internal electrode tabs are exposed or missedentirely, and missing wrap-around termination portions. Yet furtherproblems may be caused when too thin a coating of the paint-liketermination material is applied or when one portion of terminationcoating smears into another causing shorted termination lands. These andother concerns surrounding the provision of electrical termination formonolithic devices create a need to provide cheap and effectivetermination features for electronic chip components.

Yet another known option related to termination application involvesaligning a plurality of individual substrate components to a shadowmask. Parts can be loaded into a particularly designed fixture, such asthat disclosed in U.S. Pat. No. 4,919,076 (Lutz et al.), and thensputtered through a mask element. This is typically a very expensivemanufacturing process, and thus other effective yet more cost efficienttermination provisions may be desirable.

U.S. Pat. Nos. 5,880,011 (Zablotny et al.), U.S. Pat. No. 5,770,476(Stone), U.S. Pat. No. 6,141,846 (Miki), and U.S. Pat. No. 3,258,898(Garibotti), respectively deal with aspects of the formation ofterminations for various electronic components.

Additional background references that address methodology for formingmultilayer ceramic devices include U.S. Pat. Nos. 4,811,164 (Ling etal.), U.S. Pat. No. 4,266,265 (Maher), U.S. Pat. No. 4,241,378(Dorrian), and U.S. Pat. No. 3,988,498 (Maher).

While various aspects and alternative features are known in the field ofelectronic components and terminations therefor, no one design hasemerged that generally addresses all of the issues as discussed herein.The disclosures of all the foregoing United States patents are herebyfully incorporated into this application by reference thereto.

BRIEF SUMMARY OF THE INVENTION

The present subject matter recognizes and addresses various of theforegoing shortcomings, and others concerning certain aspects ofelectrical terminations and related technology. Thus, broadly speaking,a principal object of the presently disclosed technology is improvedtermination features for electronic components. More particularly, thedisclosed termination features are plated and designed to eliminate orgreatly simplify thick-film stripes that are typically printed alongportions of a monolithic device for termination purposes.

Another principal object of the presently disclosed technology is tooffer a way to guide the formation of plated terminations through theprovision of internal electrode tabs and the optional placement ofadditional anchor tabs. Both internal electrode tabs and additionalanchor tabs can facilitate the formation of secure and reliable externalplating. Anchor tabs, which typically provide no internal electricalconnections, may be provided for enhanced external terminationconnectivity, better mechanical integrity and deposition of platingmaterials.

Yet another principal object of the present subject matter is to providetermination features for electronic components whereby typicalthick-film termination stripes are eliminated or simplified, and onlyplated terminations are needed to effect an external electrodeconnection. Plated materials in accordance with the disclosed technologymay comprise metallic conductors, resistive materials, and/orsemi-conductive materials.

A still further principal object of the subject termination technologyis that termination features can be used in accordance with a variety ofmultilayer monolithic devices, including, for example, interdigitatedcapacitors, multilayer capacitor arrays, and integrated passivecomponents. Integrated passive components may include a selectcombination of resistors, capacitors, varistors, inductors, baluns,couplers, and/or other passive components.

A resultant advantage of the disclosed subject matter is thattermination features for electronic components can be effected withoutthe need for application by termination machinery, thus providing anability to yield external terminations with resolution levels that mayotherwise be unattainable. Such improved termination resolution alsoenables the provision of more terminations within a given component areaand terminations with a much finer pitch.

A general object of the present technology is to provide terminationfeatures that enable an effective solder base with reducedsusceptibility to solder leaching and also lowered insulationresistance. Configuration of exposed electrode portions and anchor tabportions is designed such that selected adjacent exposed tab portionsare decorated with plated termination material without undesiredbridging among distinct termination locations.

Yet another object of the present subject matter is that the disclosedtechnology can be utilized in accordance with a myriad of differenttermination configurations, including varied numbers and placement ofexternal terminations. Plated terminations can be formed in accordancewith a variety of different plating techniques as disclosed herein atlocations that are self-determined by the provision of exposedconductive elements on the periphery of an electronic component.

A still further object of the subject plated termination technology isto facilitate the production of cheaper and more effective electroniccomponents in an expedient and reliable manner.

Additional objects and advantages of the invention are set forth in, orwill be apparent to those of ordinary skill in the art from, thedetailed description herein. Also, it should be further appreciated bythose of ordinary skill in the art that modifications and variations tothe specifically illustrated, referenced, and discussed features hereofmay be practiced in various embodiments and uses of the disclosedtechnology without departing from the spirit and scope thereof, byvirtue of present reference thereto. Such variations may include, butare not limited to, substitution of equivalent means and features, ormaterials for those shown, referenced, or discussed, and the functional,operational, or positional reversal of various parts, features, or thelike.

Still further, it is to be understood that different embodiments, aswell as different presently preferred embodiments, of this invention mayinclude various combinations or configurations of presently disclosedfeatures or elements, or their equivalents (including combinations offeatures or configurations thereof not expressly shown in the figures orstated in the detailed description). A first exemplary embodiment of thepresent subject matter relates to a multilayer electronic component withplated terminations. Such a multilayer electronic component maypreferably include a plurality of insulating substrate layers with aplurality of electrodes interleaved among the substrate layers. Eachrespective electrode preferably has at least one tab portion extendingtherefrom that is exposed along selected edges of the plurality ofinsulating substrates. Selected of the exposed electrode tab portionsare preferably stacked within a predetermined distance of one anothersuch that a plurality of plated terminations may be formed along theperiphery of the electronic component.

Another related embodiment of the disclosed technology concerns anelectronic component such as the aforementioned first exemplaryembodiment, further including additional anchor tabs. In such anexemplary embodiment, anchor tabs may also be interspersed among theplurality of substrate layers and exposed at predetermined locationssuch that the formation of plated terminations is guided by the locationof the exposed electrode tab portions and the exposed anchor tabs. Withthe provision of a sufficient stack of exposed tabs as well as anexposed tab on each top and bottom surface of the body of dielectricmaterial aligned with the stack of exposed tabs, the formation of aplated termination that extends along an entire exposed side and thatwraps around both top and bottom sides of the electronic component ispossible and usually, but not always, desirable.

Another exemplary embodiment of the present invention corresponds to anintegrated monolithic device comprising at least two passive components.Each passive component is preferably characterized by a ceramic portionand at least one respective internal electrode layer with tab portionsextending therefrom that are exposed on selected sides of the integratedmonolithic device. Each respective passive component of the monolithicdevice also preferably includes a corresponding plurality of metallizedplating portions formed to connect selected of the respective sets oftab portions and to provide electrical connection to the electrodelayers of each respective passive component.

Anchor tabs may also be utilized in accordance with the above exemplaryintegrated monolithic device to offer additional termination options. Byplacing internal electrode tabs at selected locations within the device,a variety of different termination options becomes available. Theformation of the plated terminations is guided by the location ofexposed electrode tabs and anchor tabs, and may potentially wrap aroundto the top and bottom sides of the monolithic device.

Yet another exemplary embodiment of the present-subject matter relatesto an interdigitated capacitor comprising a plurality of interleavedelectrode and dielectric layers and characterized by respective topmostand bottommost layers. The topmost and bottommost layers of themultilayer interdigitated capacitor preferably comprise dielectric coverlayers with a thickness greater than that of the other dielectric layersin the stacked configuration. Each respective electrode layer includes aplurality of electrode tabs that extends to selected sides of theinterdigitated capacitor. The electrode tabs are preferably exposed instacked portions at selected locations along the sides of a capacitor.Anchor tabs are preferably embedded within the top and bottom coverlayers and optionally within the active layers such that an exposedstack of tabs extends along a portion of an entire side of themultilayer device. External terminations may then be plated along thestack of exposed tabs and may even wrap around to the topmost andbottommost layers if anchor tabs are positioned thereon and generallyaligned with the stack of exposed internal tabs.

Additional embodiments of the present subject matter, not necessarilyexpressed in this summarized section, may include and incorporatevarious combinations of aspects of features or parts referenced in thesummarized objectives above, and/or features or parts as otherwisediscussed in this application.

Those of ordinary skill in the art will better appreciate the featuresand aspects of such embodiments, and others, upon review of theremainder of the specification.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

A full and enabling description of the present subject matter, includingthe best mode thereof, directed to one of ordinary skill in the art, isset forth in the specification, which makes reference to the appendedfigures, in which:

FIG. 1A illustrates a generally top exploded view of a known exemplaryelectrode layer configuration for a multilayer interdigitated capacitor;

FIG. 1B illustrates a generally side perspective view of an exemplarymultilayer interdigitated capacitor with an internal electrode layerconfiguration such as the known exemplary embodiment illustrated in FIG.1A;

FIG. 2A illustrates a generally top exploded view of an exemplaryinternal electrode layer and anchor tab configuration for a multilayerinterdigitated capacitor in accordance with the present subject matter;

FIG. 2B illustrates a generally side perspective view of an exemplarymultilayer interdigitated capacitor in accordance with the presentsubject matter with internal electrode and anchor tab portions such asillustrated in FIG. 2A;

FIG. 3A illustrates a generally top exploded view of a known exemplaryinternal electrode layer configuration for a multilayer capacitor;

FIG. 3B illustrates a generally top exploded view of an exemplaryinternal electrode layer and anchor tab configuration for a multilayercapacitor in accordance with the present subject matter;

FIG. 4A illustrates a generally side perspective view of an exemplarymultilayer capacitor in accordance with the present subject matter withinternal electrode and anchor tab portions such as illustrated in FIG.3B;

FIG. 4B illustrates a generally side perspective view of an exemplarymultilayer interdigitated capacitor in accordance with the presentsubject matter, featuring internal electrode and anchor tab portionsexposed on four selected sides of the exemplary capacitor configuration;

FIGS. 5A and 5B respectively illustrate generally top views of a knownelectrode layer configuration for use in exemplary multilayer capacitorembodiments;

FIG. 5C illustrates a generally side perspective view of an exemplarymultilayer capacitor embodiment with electrode layer configurations suchas the known exemplary representations of FIGS. 5A and 5B;

FIGS. 6A and 6B respectively illustrate generally top views of anexemplary electrode layer configuration in accordance with the presentsubject matter for use in multilayer capacitor embodiments;

FIG. 6C illustrates a generally side perspective view of an exemplarymultilayer capacitor embodiment in accordance with the present subjectmatter with electrode layer configurations such as those illustrated inFIGS. 6A and 6B;

FIG. 7A illustrates a generally side perspective view of an exemplarycapacitor array with exposed electrode tabs;

FIG. 7B illustrates a generally side perspective view of an exemplarycapacitor array with plated terminations in accordance with the presentsubject matter;

FIG. 8A illustrates a generally side perspective view of an exemplarymultilayer interdigitated capacitor with plated terminations inaccordance with the present subject matter;

FIG. 8B illustrates a side cross-sectional view of an exemplarymultilayer interdigitated capacitor with exemplary plated terminationsin accordance with the disclosed technology taken along planar sectionline A-A of FIG. 8A;

FIG. 9A illustrates a generally side view, with slight top perspective,of an exemplary monolithic integrated passive component with exposedelectrode tabs and additional anchor tabs in accordance with thedisclosed technology; and

FIG. 9B illustrates a generally side view, with slight top perspective,of an exemplary monolithic integrated passive component with platedterminations in accordance with the present subject matter.

Repeat use of reference characters throughout the present specificationand appended drawings is intended to represent same or analogousfeatures or elements of the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

As referenced in the Brief Summary of the Invention section, the presentsubject matter is directed towards improved termination features formonolithic electronic components.

The subject termination scheme utilizes exposed electrode portions ofstructures such as monolithic capacitor arrays, multilayer capacitorsincluding those with interdigitated electrode configurations, integratedpassive components, and other electronic chip structures. Additionalanchor tabs may be embedded within such monolithic components to providestacked pluralities of exposed internal conductive portions to whichplated terminations may be formed and securely positioned along theperiphery of a device.

By providing additional anchor tabs on the top and bottom surfaces of achip device, wrap-around plated terminations may be formed that extendalong the side of a chip to the top and bottom layers. Such wrap-aroundterminations may be desirable in certain applications to facilitatesoldering of the chip to a printed circuit board or other suitablesubstrate.

The subject plating technology and anchor tab features may be utilizedin accordance with a plurality of different monolithic components. FIGS.1A and 1B represent aspects of known interdigitated electrode layerconfigurations wherein electrode tabs generally extend to and areexposed on two selected sides of a multilayer component. Aspects ofplated terminations in accordance with the present subject matter arethereafter presented with respect to FIGS. 2A and 2B, which also concernmultilayer component embodiments with exposed conductive portions of twoselected sides of a device.

FIG. 3A illustrates aspects of a known electrode layer configurationwith electrode tabs for exposure on one selected side of a multilayerelectronic device. FIGS. 3B and 4A, respectively, relate to improvementsof the exemplary embodiment presented in FIG. 3A, providing for anexemplary multilayer capacitor with internal electrode tabs exposed onone selected side of the capacitor and featuring anchor tabs inaccordance with the present technology. FIG. 4B relates to an exemplarymultilayer interdigitated component with internal electrode tabs andanchor tabs exposed of four selected sides of the component inaccordance with the present subject matter.

Still further exemplary embodiments of the present subject matter relateto the multilayer capacitor configurations illustrated in FIGS. 6Athrough 6C, respectively, which are improvements to the exemplarymultilayer capacitor configurations of FIGS. 5A through 5C,respectively. Additional embodiments of the disclosed technology arepresented with reference to the exemplary capacitor arrays of FIGS. 7Aand 7B. FIGS. 8A and 8B then represent aspects of the subject platedtermination features, while FIGS. 9A and 9B concern an exemplaryintegrated passive component with selective terminations in accordancewith the present subject matter.

It should be noted that each of the exemplary embodiments as presentedherein should not insinuate limitations of the disclosed technology.Features illustrated or described as part of one embodiment can be usedin combination with another embodiment to yield further embodiments.Additionally, certain features may be interchanged with similar devicesor features not mentioned yet which perform the same, similar orequivalent function.

Reference will now be made in detail to the presently preferredembodiments of the disclosed technology. Referring to the drawings, FIG.1A illustrates a known exemplary configuration of electrode layers 10and 12 with electrode tabs 14 for use in a multilayer interdigitatedcapacitor or capacitor array. Electrode layers are arranged in parallelwith tabs 14 extending from the layers such that electrode tabsextending from alternating electrode layers 10 and 12 are aligned inrespective columns. The exemplary illustration depicts four suchelectrode layers with corresponding tabs 14, but typical arrangements asutilized with the present technology may in some instances contain manymore electrode layers and respective tabs. This feature provides theoption of creating capacitive elements with a large range of capacitancevalues (by choosing the number of electrodes).

The exemplary electrode layer configuration of FIG. 1A is notrepresentative of a finished capacitor embodiment. Instead, FIG. 1Aprovides a reference for an intermediate aspect of exemplary capacitorand capacitor array configurations. The electrode layer configuration ofFIG. 1A can be utilized in accordance with an exemplary multilayerinterdigitated capacitor such as displayed in FIG. 1B.

An interdigitated capacitor typically consists of a plurality ofelectrode layers, such as those shown in FIG. 1A disposed in a body ofdielectric material 18, such as seen in the exemplary interdigitatedcapacitor configuration 16 of FIG. 1B. Electrode layers 10 and 12 aredisposed in the dielectric material 18 such that electrode tabs 14extend to and are exposed at two sides of IDC embodiment 16. Exemplarymaterials for such electrode layers may include platinum, nickel, apalladium-silver alloy, or other suitable conductive substances.Dielectric material 18 may comprise barium titanate, zinc oxide, aluminawith low-fire glass, or other suitable ceramic or glass-bondedmaterials. Alternatively, the dielectric may be an organic compound suchas an epoxy (with or without ceramic mixed in, with or withoutfiberglass), popular as circuit board materials, or other plasticscommon as dielectrics. In these cases the conductor is usually a copperfoil which is chemically etched to provide the patterns.

Exemplary IDC embodiment 16 may alternatively be viewed as a multilayerconfiguration of alternating electrode layers and dielectric layers inportion 20 of the device. IDC 16 is typically further characterized by atopmost dielectric layer 22 and bottommost dielectric layer 24 that maygenerally be thicker than other dielectric layers of IDC configuration16. Such dielectric layers 22 and 24 act as cover layers to protect thedevice and provide sufficient bulk to withstand the stress ofglass/metal frit that may be fired to a capacitor body. Known capacitorembodiments have utilized the multilayer arrangement of FIG. 1B, and thepresent subject matter utilizes aspects of such configuration 16 inaccordance with additional features disclosed herein.

A multilayer IDC component 16 such as that of FIG. 1B that incorporatesthe known exemplary electrode layer configuration of FIG. 1A ischaracterized by electrode portions 14 that are exposed on two selectedsides of IDC component 16. Other exemplary internal electrodeconfigurations may be employed in a multilayer component such thatinternal electrode portions are exposed at different locations and/or ondifferent numbers of sides of the device.

For example, consider the exemplary internal electrode layerconfiguration illustrated in the exploded view of FIG. 3A. Alternatingelectrode layers 26 and 28 are provided with electrode tab portions 30extending toward a single selected direction. Electrode tabs 30 for eachset of alternating electrode layers are preferably arranged in a stackedconfiguration such that, for instance, tabs 30 from electrode layers 26are aligned in two respective columns. A similar alignment situationpreferably holds for tabs 30 of electrode layers 28. A multilayercapacitor or other passive component that utilizes the exemplaryinternal electrode configuration of FIG. 3A will typically be configuredsuch that electrode tab portions 30 are exposed on a single selectedside of the component.

Yet another exemplary internal electrode layer configuration providesfor electrode tabs that are exposed on four sides of a multilayerinterdigitated component. Such internal electrode layers may be similarto the configuration depicted in FIG. 1A wherein each alternatingelectrode layer 10 and 12 has additional tab portions on the sides ofthe layers adjacent to the sides from which tab portions 14 extend.

A still further exemplary electrode layer configuration andcorresponding multilayer capacitor embodiment is depicted in FIGS. 5Athrough 5C, respectively. A first plurality of internal electrode layers32 such as in FIG. 5A are interleaved with internal electrode layers 34,such as in FIG. 5B, in a body of dielectric material 36 to form amultilayer capacitor 38 such as in FIG. 5C. In such exemplary multilayercomponent 38, portions 40 of one set of electrode layers 32 or 34 isexposed on side 42 of component 38. The portions of the other set ofelectrode layers 32 or 34 is thus exposed on the side of the deviceopposite of side 42 (not seen in the drawing).

Referring again to FIG. 1B, a typical conventional termination for IDCembodiment 16 and for other monolithic electronic components comprises aprinted and fired thick-film stripe of silver, copper, or other suitablemetal in a glass matrix, on top of which is plated a layer of nickel topromote-leach resistance, and is followed by a layer of tin or solderalloy which protects the nickel from oxidation, and promotes an easilysoldered termination.

A thick-film stripe in accordance with such type of termination alsotypically requires printed application by a termination machine andprinting wheel or other suitable component to transfer a metal-loadedpaste. Such printing hardware may have resolution limits that make ithard to apply thick-film stripes, especially to smaller chips. A typicalexisting size for an IDC 16 or other electronic component is about onehundred and twenty mils (thousandths of an inch) by sixty mils along thetwo opposing sets of sides with a thickness from top to bottom layers ofabout thirty mils. When more than four terminations need to be appliedto a part this size or terminations are desired for a part with smallerdimensions, the resolution levels of specialized termination machineryoften becomes a limitation in applying effective termination stripes.

The present subject matter offers a termination scheme that eliminatesor greatly simplifies the provision of such typical thick-filmtermination stripes. By eliminating the less-controlled thick filmstripe, the need for typical termination printing hardware is obviated.Termination features in accordance with the disclosed technology focusmore on the plated layer of nickel, tin, copper, etc. that is typicallyformed over a thick-film termination stripe.

Consider the exemplary capacitor array configuration 44 presented inFIG. 7A. Capacitor array 44 is characterized by a plurality of internalelectrodes and corresponding electrode tabs 46 embedded in a body ofdielectric material 48. As opposed to the electrode layers of exemplaryIDC configuration 16, the electrode tabs 46 of capacitor array 44typically correspond to separate internal electrodes. By subjectingcapacitor array 44 or other electronic component with similarly exposedelectrode tabs to an electroless plating solution, for example nickel orcopper ionic solution, the formation of plated terminations 50, such asis shown in FIG. 7B, is preferably effected. Exposure to such solutionenables the exposed electrode tabs 46 to become deposited with nickel,copper, tin or other metallic plating. The resulting deposition ofplated material is preferably enough to effect an electrical connectionbetween adjacent electrode tabs 46 in a stacked column. The distancebetween adjacent electrode tabs in a column of tabs should preferably beno greater than about ten microns to ensure proper plating. The distancebetween adjacent columnar stacks of electrode tabs 46 should thus begreater by at least a factor of 2 than this minimum distance to ensurethat distinct terminations 50 do not run together. In some embodimentsof the present technology, the distance between adjacent columnar stacksof exposed metallization is about four times the distance betweenadjacent exposed electrode tabs 46 in a particular stack. By controllingthe distance between exposed internal conductor portions, terminationconnectivity can be manipulated to form bridged or non-bridgedterminations depending on the desired termination configuration.

Plated terminations 50 are thus guided by the positioning of the exposedelectrode tabs 46. This-phenomena is hereafter referred to as“self-determining” since the formation of plated terminations 50 isdetermined by the configuration of exposed metallization at selectedperipheral locations on multilayer component, or capacitor array, 44.The exposed internal electrode tabs 46 also help anchor terminations 50to the periphery of capacitor array 44′, which corresponds to amultilayer capacitor embodiment such as 44 of FIG. 7A with the additionof plated terminations 50. Further assurance of complete platingcoverage and bonding of the metals may be achieved by includingresistance-reducing additives in the plating solution. A still furthermechanism for enhancing the adhesion of metallic deposit that forms thesubject plated terminations is to thereafter heat the component inaccordance with such technologies as baking, laser subjection, UVexposure, microwave exposure, arcwelding, etc.

The plated terminations 50 of FIG. 7B may be sufficiently formed forsome component applications, but sometimes the exposed metallizationfrom internal electrode tabs is insufficient to form theself-determining terminations of the present technology. In such case,it may be-beneficial, and in some cases necessary, to provide additionalanchor tabs embedded within select portions of a monolithic component.Anchor tabs are short conductive tabs that typically offer no electricalfunctionality to a component, but mechanically nucleate and secureadditional plated termination along the periphery of a monolithicdevice. Exposed anchor tabs in combination with exposed internalelectrode portions can provide sufficient exposed metallization tocreate more effective self-determining terminations.

For instance, consider the exploded configuration of exemplary internalmetallization illustrated in FIG. 2A. Alternating electrode layers 52and 54 are provided in a similar configuration to the electrode layersof FIG. 1A, with electrode tab portions 56 extending from selectedlocations of electrode layers 52 and 54. Additional anchor tabs 58 arealso preferably provided in the same plane as active electrode layers 52and 54 such that they are also exposed at selected locations along amultilayer component, yet offer no internal electrical connections.Additional anchor tabs may also be provided in the cover layers of amultilayer component and exposed along selected sides such that theformation of self-determining plated terminations that extend along evenmore of the component periphery is enabled.

With reference to FIG. 2B, multilayer component 60 corresponds to anexemplary multilayer capacitor embodiment in accordance with the presentsubject matter. Portion 62 of multilayer component 60 preferablycomprises the exemplary interdigitated electrode layer and anchor tabconfiguration of FIG. 2A embedded within a portion of dielectricmaterial. Solid lines 56 along the periphery of portion 62 are intendedto represent exposed portions of the electrode tabs 56 of FIG. 2A, anddashed lines 58 along the periphery of portion 62 represent exposedanchor tabs 58. Additional anchor tabs may be embedded within dielectriccover layers 64 and 66 (exposed portions of which are represented bydashed lines 68) to further provide an arrangement of exposedmetallization for facilitating the formation of self-determining platedterminations in accordance with the present subject matter. Internalanchor tabs are preferably aligned in a generally similar column as astack of internal electrode tabs such that all internal tabs arearranged in common stacks.

For some component applications, it may be preferred that terminationsnot only extend along the entire width of a component, but also wraparound to the top and bottom layers. In this case, external anchor tabs70 may be positioned on top and bottom layers of multilayer IDC 60 suchthat plated terminations can form along the sides and on portions of thetop and bottom layers, forming extended solder lands. For example, theprovision of embedded internal anchor tabs 58 and 68 and external anchortabs 70 along with existing exposed electrode tabs 56 in IDC 60, such asdepicted in FIG. 2B, would facilitate the formation of wrap-aroundplated terminations 72, such as in FIG. 8A.

There are several different techniques that can potentially be used toform plated terminations, such as terminations 72 on multilayercomponent embodiment 74 of FIG. 8A. As previously addressed, a firstmethod corresponds to electroplating or electrochemical deposition,wherein an electronic component with exposed conductive portions isexposed to a plating solution such as electrolytic nickel orelectrolytic tin characterized by an electrical bias. The componentitself is then biased to a polarity opposite that of the platingsolution, and conductive elements in the plating solution are attractedto the exposed metallization of the component. Such a plating techniquewith no polar biasing is referred to as electroless plating, and can beemployed in conjunction with electroless plating solutions such asnickel or copper ionic solution.

In accordance with electrochemical deposition and electroless platingtechniques, a component such as IDC 74 of FIG. 8A, is preferablysubmersed in an appropriate plating solution for a particular amount oftime. With certain embodiments of the present subject matter, no longerthan fifteen minutes is required for enough plating material to depositat exposed conductive locations along a component such that buildup isenough to spread the plating material in a perpendicular direction tothe exposed conductive locations and create a connection among selectedadjacent exposed conductive portions.

Another technique that may be utilized in accordance with the formationof the subject plated terminations involves magnetic attraction ofplating material. For instance, nickel particles suspended in a bathsolution can be attracted to similarly conductive exposed electrode tabsand anchor tabs of a multilayer component by taking advantage of themagnetic properties of nickel. Other materials with similar magneticproperties may be employed in the formation of plated terminations.

A still further technique regarding the application of platedtermination material to exposed electrode tabs and anchor tabs of amultilayer component involves the principles of electrophoretics orelectrostatics. In accordance with such exemplary technology, a bathsolution contains electrostatically charged particles. An IDC or othermultilayer component with exposed conductive portions may then be biasedwith an opposite charge and subjected to the bath solution such that thecharged particles are deposited at select locations on the component.This technique is particularly useful in the application of glass andother semiconductive or nonconductive materials. Once such materials aredeposited, it is possible to thereafter convert the deposited materialsto conductive materials by intermediate application of sufficient heatto the component.

One particular methodology for forming plated terminations in accordancewith the disclosed technology relates to a combination of theabove-referenced plating application techniques. A multilayer componentmay first be submersed in an electroless plating solution, such ascopper ionic solution, to deposit an initial layer of copper overexposed tab portions, and provide a larger contact area. The platingtechnique may then be switched to an electrochemical plating systemwhich allows for a faster buildup of copper on the selected portions ofsuch component.

In accordance with the different available techniques for platingmaterial to exposed metallization of a multilayer component inaccordance with the present technology, different types of materials maybe used to create the plated terminations and form electricalconnections to internal features of an electrical component. Forinstance, metallic conductors such as nickel, copper, tin, etc. may beutilized as well as suitable resistive conductors or semi-conductivematerials, and/or combinations of selected of these different types ofmaterials.

A particular example of plated terminations in accordance with thepresent subject matter wherein plated terminations comprise a pluralityof different materials is discussed with reference to FIG. 8B. FIG. 8Bprovides a cross-sectional view of component 74 of FIG. 8A taken alongplanar section line A-A in accordance with a particular exemplaryembodiment of plated terminations 72. It should be appreciated thatterminations 72 may comprise only a first plating layer and noadditional layers as presented in this example. Due to such potentialfor variation in the number of plating layers in the multilayercomponent and termination embodiments of FIGS. 8A and 8B, the tworespective embodiments are labeled as 74 and 74′ respectively, and suchreference is not intended to insinuate additional variations between thetwo respective embodiments.

A first step in the formation of the terminations illustrated in FIG. 8Binvolves submersing a component in an electroless copper platingsolution such that a layer of copper 76 or other metal is depositedalong the periphery of component 74′ where portions of internal anchortabs 58 and 68, exposed internal electrode tabs extending from electrodelayers 52 and 54, and external anchor tabs 70 are exposed. The tab areacovered with metallic plating 76 can then be covered with aresistor-polymeric material 78 and then plated again with metalliccopper or other material 80.

A still further plating alternative corresponds to forming a layer ofmetallic plating, and then electroplating a resistive alloy over suchmetallic plating. Plating layers can be provided alone or in combinationto provide a variety of different plated termination configurations. Afundamental of such plated terminations is that the self-determiningplating is configured by the design and positioning of exposedconductive portions along the periphery of a component.

Such particular orientation of internal electrode portions and anchortabs may be provided in a variety of different configurations tofacilitate the formation of plated terminations in accordance with thepresent subject matter. For instance, consider the exemplary internalconductive configuration of FIG. 3B with electrode layers 26 and 28.Electrode tabs 30 and internal anchor tabs 82 may be provided in a bodyof dielectric material to create a multilayer component similar to thatof FIG. 4A. Additional internal anchor tabs 84 and external anchor tabs86 may also be provided. One of the prescribed plating techniques maythen be utilized to form plated terminations on multilayer component 88along the exposed areas of metallization.

Yet another exemplary multilayer component in accordance with aspects ofthe present subject matter is represented as component 90 in FIG. 4B.Internal electrode layers are provided with electrode tabs that extendto four sides of component 90. Additional internal anchor tabs 94 may beinterleaved with exposed electrode tabs 92. Still further internalanchor tabs 96 may be embedded within cover layers of component 90 toprovide for expanded plated terminations. The provision of externalanchor tabs 98 could facilitate the formation of wrap-around platedterminations.

A still further application of the presently disclosed technologyrelates to more general multilayer component configurations, such asdepicted in FIGS. 6A, 6B and 6C. Electrode layer 100 of FIG. 6A andelectrode layer 102 of FIG. 6B are provided in respective T-shapedconfigurations such that electrode tab portions 104 extend from therespective electrode layers. When electrode layers 100 and 102 areinterleaved with dielectric layers to form a multilayer ceramic device,such as shown in FIG. 6C, each electrode tab portion 104 is exposed ontwo adjacent sides of the device 108. Anchor tab portions 106 may alsobe provided within the electrode layer planes such that exposedconductive portions are aligned along the opposing peripheral sides ofdevice 108, to facilitate formation of plated electrodes thereon.

Another example embodying aspects of the disclosed technology ispresented with respect to FIGS. 9A and 9B. FIG. 9A represents anintegrated passive component 110, comprising a combination of passivecomponents provided in a single monolithic structure. Integratedcomponent 110 may include a selected combination of resistors,varistors, capacitors, inductors, couplers, baluns, and/or other passivecomponents. Each distinct passive component is typically characterizedby at least one conductive electrode-like portion from which at leastone electrode tab portion 112 extends and is exposed along the peripheryof component 110.

An integrated passive component 110, such as that represented by FIG.9A, may have a plurality of different internal electrode arrangements asshown. Corresponding electrode tabs 112 may be provided in symmetricalor nonsymmetrical configurations and may be grouped in a variety offashions. An important feature is that exposed electrode tabs 112 may bearranged within component 110 to facilitate the formation of selectiveplated terminations. In addition, internal anchor tabs 114 and/orexternal anchor tabs 116 may also be provided with an integrated passivecomponent to create additional selective termination arrangements. Forexample, consider the exposed tab arrangement of FIG. 9A, with numerousexposed internal electrode tabs 112, internal anchor tabs 114, andexternal anchor tabs 116. Subjecting such configuration to a platingsolution in accordance with variations of the presently disclosedtechnology would preferably effect the formation of a plurality ofplated side terminations 118 and plated wrap-around terminations 120,such as in FIG. 9B. Integrated passive component, or multilayerelectronics device, 110′ simply corresponds to an integrated passivecomponent such as 110 of FIG. 9A with the addition of platedterminations 118 and 120, respectively. Thus, tabs of an integratedpassive component can be designed whereby plated terminations can beformed among different electrodes and different component layers.

It should be appreciated that the monolithic component embodimentspresented in FIGS. 1A through 9B, respectively, are presented merely asexamples of the disclosed technology, including intermediate aspectsthereof. In most of the examples, four or more general columns ofelectrodes are depicted, but a fewer or greater number of electrodecolumns are possible, depending on the desired component configuration.It is possible to form plated terminations along any selected portion ofany selected component side in accordance with the disclosed technology.Such plated terminations may include a single layer of plated conductivematerial, resistive material, or semi-conductive material, or amultilayer combination of selected of such materials.

It should be appreciated that internal anchor tabs and external anchortabs may selectively be used for different termination preferences toprovide different sizes of side terminations or wrap-aroundterminations. IDC embodiments displayed and described herein thatfeature both internal and external anchor tabs may, for instance, onlyutilize internal anchor tab features when wrap-around terminations arenot preferred for a particular application. Different combinations ofboth internal and external anchor tabs with existing exposed electrodetabs on a variety of different multilayer components can yield numerouspotential termination schemes for a device.

While the present subject matter has been described in detail withrespect to specific embodiments thereof, it will be appreciated thatthose skilled in the art, upon attaining an understanding of theforegoing may readily adapt the present technology for alterations to,variations of, and equivalents to such embodiments. Accordingly, thescope of the present disclosure is by way of example rather than by wayof limitation, and the subject disclosure does not preclude inclusion ofsuch modifications, variations, and/or additions to the present subjectmatter as would be readily apparent to one of ordinary skill in the art.

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 30. A method of making a multi-layer electronic component,comprising the steps of: providing a plurality of insulating substrateseach having an upper and a lower surface, said substrates each beingdelimited laterally by edges; interleaving a plurality of electrodesbetween selected of said plurality of insulating substrates; exposingselected portions of said electrodes along at least one edge of saidsubstrates; and plating at least one layer of termination material onsaid exposed portions of said electrodes.
 31. The method of claim 30,further comprising the step of continuing the plating process until theexposed portions of selected of said electrodes are connected.
 32. Themethod of claim 30, wherein the step of plating is performed using anelectroless process followed by an electrochemical process.
 33. Themethod of claim 30, wherein the step of plating is performed using anelectroless process.
 34. The method of claim 33, wherein the electrolessprocess comprises submersing the multi-layer electronic component in anelectroless copper plating solution to form a copper termination layer.35. The method of claim 34, further comprising the step of covering thecopper termination layer with a resistive layer.
 36. The method of claim35, further comprising the step of plating the resistive layer with aconductive layer.
 37. The method of claim 30, further comprising thesteps of: providing electrically isolated anchor tabs interleaved atselected locations between the insulating substrates; and exposingportions of said anchor tabs at selected edges of the insulatingsubstrates; wherein said plating step additionally plates terminationmaterial on said exposed portions of said anchor tabs.
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